Process for making non-woven insulating sheeting and products of such process

ABSTRACT

A process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

STATEMENT OF PRIORITY

The present application is a divisional application of, and claims priority to U.S. Nonprovisional application Ser. No. 14/530,496, entitled “Process for Making Non-Woven Insulating Sheeting and Products of Such Process,” and filed Oct. 31, 2014, which claims priority to U.S. Provisional Application No. 61/898,400, titled “Process for Making Insulating Sheeting and Products of Such Process” and filed Oct. 31, 2013.

TECHNICAL FIELD

The present disclosure relates to processes for the production of non-woven insulating materials and to products of such processes.

BACKGROUND

Insulating materials, in particular those used for clothing, are of importance ranging from mere comfort to determining survival. Wherever in the spectrum use of insulating materials falls, there is always the multi-point compromise between performance, bulk, weight, cost and durability. The optimal insulating material will be that which provides the desired (or needed) performance (often expressed as “CLO” rating), with the least bulk (volume), least weight, least cost, and greatest durability. Often added to this calculus is the impact upon, and the constituent material's reaction to moisture, whether from a clothing wearer, from external sources, or both. Further still, manufacturing costs will impact the selection of insulating materials and/or the pricing of a finished garment.

Therefore, selection of an insulating material, particularly for garments, is always the product of compromise. For example, insulation performance is nearly always achievable, even as again the harshest environmental conditions. However, optimal performance comes, to some degree, with a negative impact on most other variables: (1) considerable (even to the point of impracticability) bulk or weight; (2) prohibitive materials and/or manufacturing costs; and/or (3) durability, just to name some. Practical and/or attractive bulk distribution of insulating materials in a garment (for flexibility or even aesthetics) may also come, for example, at the expense of protection from temperature extremes, as well as with higher material and/or manufacturing costs.

With respect to over-all performance, wool typically represents the best choice for most any garment-related insulation need. Wool exhibits exemplary insulation characteristics for which it has been known throughout history. This is attributable, largely, to the fiber's inherent crimping and the related mutual, mechanical separation of fibers to maintain “dead air” in between them. Wool fibers provide approximately three times the CLO per unit weight than does polyester and similar synthetic fibers. However, wool also exhibits moisture-handling characteristics that no synthetic, or even natural fiber alternative can match.

Each wool fiber (measuring about a thousandth of an inch in diameter, depending on the grade) consists of a bundle of corticle cells, made up of polypeptide chains arranged in coils. These corticle cells are wrapped up in a scaly outer layer called a cuticle, which in turn is covered by a filmy skin called an epicuticle. The epicuticle actually sheds drops of water. In addition, raindrops, for example, are less likely to break up on the surface of wool and seep through, as with other fabrics, since the “fuzziness” of the fibers cushions the fall. Even so, as opposed to reactions from exterior moisture (rain, for example) handling moisture (perspiration) from the wearer is, in many cases, the most important issue for insulating garments. And therein lie many of the incomparable benefits of wool as a garment insulating material.

The epicuticle of wool fibers have tiny pores that allow water vapor to pass through to the core, where it's chemically absorbed. Wool fiber can entrap up to 30 percent of its own weight in moisture without feeling wet, only to later release it through evaporation.

When used as an insulating material lying close to a wearer's skin, wool's ability to manage moisture in this manner will contribute to maintaining an essential “boundary layer” of body temperature, “dead air” that will keep the wearer at a comfortable (or even survivable) temperature. Examples of woven wools ability to protect wearers from extreme temperatures are found in relation to the VISCO-WOOL products, while the non-woven, wool-based fabrics are capable of even superior performance, for reasons already discussed.

In theory, at least, wool in any form would be an incomparable, superior choice for garment insulation (at least were cost not to be an issue). Wool is still superior in many ways (moisture-handling characteristics, among them), but conventional fabrication of wool-based materials involves the ancient process of first creating yarn, from which fabric is woven. Wool fibers are compressed in the yarn environment, and this collapses much of the dead air space otherwise present in non-spun or woven wool fibers. Thus, more wool fabric is needed to achieve the same insulation performance than would be needed, were wool fibers to somehow be practicably used. This latter issue, however, relates to durability—simply filling a garment or portion of a garment's contained spaces with wool fibers would in no way be satisfactory, in part, because of the inevitable settling and bunching of the fibers. Prior to the present invention, there has been no practical way (regardless of cost) to use non-compressed, non-woven wool fibers as a garment insulation material.

Then, there is the cost issue. Despite the clear superiority of wool as a garment insulating material, costs alone have driven much of the garment insulation adoption toward synthetic fibers. At the time of this writing, manufacturers' costs for performance-comparable wool fabric useful for garment insulation are multiples of the costs for synthetic batting. While the choice of synthetics is most often made, this (as mentioned above) comes at a cost of bulk, garment attractiveness, and moisture-handling ability. The aesthetics of the garment is also often a casualty of the choice of the bulky synthetic batting, unless insulation performance is sacrificed through use of lesser material. In any event, nothing among the synthetics choices will match wool's inherent moisture management characteristics (often reflected in the old saying about wool: “Warm, even when wet”).

SUMMARY OF THE INVENTION

In view of the foregoing, it would well-serve producers and consumers alike to provide a process by which non-woven wool fibers could be fashioned into a durable, low-volume, high performance insulation material for garments (and other products for which insulation is needed), and in a manner, and consuming raw materials such that the end product is cost-competitive with conventional alternatives (synthetic or woven, yarn-based wool or other natural fiber fabrics). Were such a process (and the products thereof) to be available, consumers would benefit from all of the superior characteristics of wool as an insulating and moisture-managing material, while not sacrificing in the realms of cost, durability, bulk, or aesthetics. In addition, a return to wool as a base material for insulation would lessen the environmental impact of synthetics manufacturing and would support domestic wool producers.

The present disclosure introduces various illustrative embodiments for a process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

It is another object of the present disclosure to provide a non-woven insulating fabric that includes a batting comprised of wool fibers mechanically oriented in a fashion capable of being used for insulation, and a scrim having the batting tacked thereto via a loom having needles coupled to a needle board. The needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the batting is tacked to the scrim primarily without the use of an adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the present invention, and should not be viewed as an exclusive embodiments. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to one having ordinary skill in the art and the benefit of this disclosure.

FIG. 1 depicts a loom capable of generating wool batting from wool fibers, according to one or more embodiments.

FIG. 2 depicts a loom capable of tacking batting to a scrim, according to one or more embodiments

FIG. 3 depicts an enlarged cross-sectional view of one of the needles of a needle board, according to one or more embodiments.

FIG. 4 is a flow diagram of a process for making insulating fabric, according to one or more embodiments.

DETAILED DESCRIPTION

The present disclosure relates to processes for the production of non-woven insulating materials and to product of such processes.

An illustrative embodiment includes a process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

Other illustrative embodiments includes a non-woven insulating fabric that includes a batting comprised of wool fibers mechanically oriented in a fashion capable of being used for insulation, and a scrim having the batting tacked thereto via a loom having needles coupled to a needle board. The needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the batting is tacked to the scrim primarily without the use of an adhesive.

Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout the various views and embodiments of a unit. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of the ordinary skill in the art will appreciate the many possible applications and variations based on the following examples of possible embodiments. As used herein, the “present disclosure” refers to any one of the embodiments described throughout this document and does not mean that all claimed embodiments must include the referenced aspects.

FIG. 1 depicts a loom 100 capable of generating wool batting from wool fibers, according to one or more embodiments. As depicted, the loom 100 includes an intake 102, a means for mechanically orienting the wool fibers 104, and an output portion 106. In exemplary operations, the loom 100 may be fed clumps of wool fibers 108 via the intake 102. The loom 100 then processes the wool fibers 108 into more individualized strands, and then combines or mechanically re-orients the strands together via the means for mechanically orienting wool fibers 104, thereby forming a batting 110, as known to those skilled in the art. Such means for mechanically orienting wool fibers 104 may be, for example and without limitation, one or more wire cylinders 112, which comb and align the wool fibers 108, carting and crosslapping the wool fibers 108 into the batting 110. In some embodiments, the wool fibers 108, and therefore the batting 110, may be one of a Merino or Alpaca superwashed wool fibers as known to those skilled in the art. In further embodiments, the batting may be a weight ranging from 70 to 300 grams per square meter.

FIG. 2 depicts a loom 200 capable of tacking the batting 110 to a scrim 210, according to one or more embodiments. In some embodiments, for example and without limitation, the loom 200 may be a Hunter, model 54, double beam, down-stroke needle loom, as known to those skilled in the art. As depicted, the loom 200 (hereinafter, the “needle loom 200”), includes an intake 202, a needle board 204 that includes needles 206 coupled thereto, and an output 208. FIG. 2 also depicts the batting 110 and a scrim 210 arranged near the intake 202 of the needle loom 200, wherein the batting 110 and scrim 210 are tacked together by the needle loom to form an insulating fabric 212. In some embodiments, the scrim 210 may be a weight ranging from 8 to 34 grams per square meter.

In exemplary operations, the batting 110 and the scrim 210 are arranged near the intake 202 of the needle loom 200. The batting 110 and the scrim 210 are they conveyed into the needle loom 200, wherein they are tacked together via the needle board 204 and the needles 206. For example, the needle board 204 may move in a first direction A (e.g., in a downward direction or a down-stroke as implemented by some looms), wherein the needles 206 engage with and pull one or more wool fibers (e.g. wool fibers 108) in the direction A, and through the batting 210. Afterwards, the needle board 204 may move in a second direction B, opposite of direction A, (e.g. in an upward direction or an up-stroke as implemented by some looms), wherein the needles 206 disengage or release the wool fibers 108, thereby leaving the wool fibers 108 intertwined with the scrim 210 (i.e., tacked to the scrim 210) and forming the insulating fabric 212.

In some embodiments, the production width of the needle loom 200 is a multiple of 30, 45, 36, or 72 inches, including have a maximum production width of 160 inches. In further embodiments, the loom speed (i.e., the speed the insulating fabric 212 is produced) may range from 12 to 30 feet per minute.

Briefly referring to FIG. 3, depicted is an enlarged cross-sectional view of one of the needles 206 of the needle board 204, according to one or more embodiments. As depicted, the needle 206 includes a body 302 having barbed edges (shown as barbs 304), and a pointed end 306. Such barbs 304 enable the exemplary operation previously described. For example, as the needle 206 moves in the first direction A towards the batting 110, the barbs 304 may engage with one or more wool fibers 108, thereby pulling the wool fibers 108 through the scrim 210, and causing intertwinement of the two.

Afterwards, the needle may move in the second direction B, wherein the barbs 304 disengage from the wool fibers 108, thereby leaving the wool fibers 108 intertwined with the scrim 210 (i.e., tacked to the scrim 210) and forming the insulating fabric 212. Advantageously, such process of tacking enables a coupling of the batting 110 to the scrim 210 primarily without the use or employment of adhesives, resins, glues, or the like. Substantial reduction or elimination of such additional chemicals both reduces cost to manufacture the insulation fabric 212, and enables such manufacturing to be environmentally friendly.

Referring now back to FIG. 2, in some embodiments, a loom punch speed (the rate at which the needle board 204 completes one cycle of moving in the first direction A and back in the second direction B) may range from 200 to 400 strokes per minute. In further embodiments, a needle penetration per square inch (NPPSI) of the needle loom 200 may range from 200 to 450 NPPSI. Moreover, in some embodiments, the needle board 204 may have a needle density ranging from 75 to 115 needles 206 per linear board inch. In other embodiments, the loom punch speed is approximately 400 strokes per minute, the NPPSI is one of a range from 350 to 450, the scrim is a weight of approximately 17 grams per square meter, and the loom speed is approximately 25 feet per minute. Advantageously, such embodiments enable manufacturing of insulation with various bulk weight, CLO ranges, and durability.

FIG. 4 is a flow diagram of a process 400 for making insulating fabric, according to one or more embodiments. At block 402, wool fibers are mechanically oriented into a batting capable of being used for insulation. Such may occur via a loom, where chunks or clusters of the wool fibers are arranged at an input of the loom and conveyed therethrough. The wool fibers are broken into more individualized strands, and then recombined and reoriented back together, for example, via one or more wire cylinders or other similar means as known to those skilled in the art which may comb and crosslap the wool fibers into a resulting batting. In some embodiments, the wool fibers, and therefore the batting, may be one of a Merino or Alpaca superwashed wool fibers as known to those skilled in the art. In further embodiments, the batting may be a weight ranging from 70 to 300 grams per square meter.

At block 404, the batting is tacked to a scrim with a loom via needles coupled to a needle board of the loom (thus, hereinafter, the “needle loom”). In some embodiments, for example and without limitation, the needle loom may be a Hunter, model 54, double beam, down-stroke needle loom, as known to those skilled in the art. In other embodiments, the scrim 210 may be a weight ranging from 8 to 34 grams per square meter.

The needles may each include a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction (e.g., in a downward direction or a down-stroke as implemented by some looms), and substantial disengagement with stroking in a second direction (e.g., in an upward direction or an up-stroke as implemented by some looms), thereby substantially coupling the batting to the scrim to form the insulation fabric.

More particularly, in exemplary operation, the barbed edges act to couple the batting to the scrim by first engaging with one or more of the wool fibers of the batting when stroking in the first direction (e.g., the downward direction or down-stroke). As the needle moves through the scrim, the wool fibers are correspondingly pulled through the scrim, thereby causing intertwinement of the batting to the scrim. Afterwards, the needle moves in a second direction (e.g., in the upward direction or up-stroke) and the barbs disengage from the wool fibers, thereby leaving the wool fibers intertwined with the scrim (i.e., tacked to the scrim) and forming the insulating fabric. Advantageously, such process of tacking enables coupling of the batting to the scrim primarily without the use or employment of adhesives, resins, glues, or the like. In turn, due to the substantially reduction or elimination of additional chemicals, manufacturing costs are reduced, and the insulation fabric is more environmentally friendly.

In some embodiments, the production width of the needle loom is a multiple of 30, 45, 36, or 72 inches, including have a maximum production width of 160 inches. In further embodiments, the loom speed (i.e., the speed the insulating fabric is produced) may range from 12 to 30 feet per minute. In other embodiments, a loom punch speed (the rate at which the needle board completes one cycle of moving in the first direction and back in the second direction) may range from 200 to 400 strokes per minute. In further embodiments, a needle penetration per square inch (NPPSI) of the needle loom 200 may range from 200 to 450 NPPSI. Moreover, in some embodiments, the needle board may have a needle density ranging from 75 to 115 needles per linear board inch. In other embodiments, the loom punch speed is approximately 400 strokes per minute, the NPPSI is one of a range from 350 to 450, the scrim is a weight of approximately 17 grams per square meter, and the loom speed is approximately 25 feet per minute. Advantageously, such embodiments enable manufacturing of insulation with various bulk weight, CLO ranges, and durability.

Although the disclosure has been described and illustrated with respect to exemplary objects thereof, it will be understood by those skilled in the art that various other changes, omissions, and additions may be made therein and thereto without departing from the scope of the present disclosure. 

What is claimed is:
 1. A process for making insulating fabric, comprising: mechanically orienting wool fibers into a batting capable of being used for insulation; and tacking said batting to a scrim with a loom via needles coupled to a needle board of said loom, wherein said needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with said batting when stroking in a first direction, and substantial disengagement with said batting when stroking in a second direction, and wherein said tacking is performed primarily without the use of an adhesive.
 2. The process of claim 1, wherein said wool fibers are one of a Merino or Alpaca superwashed wool fibers.
 3. The process of claim 1, wherein a loom punch speed is one from a range of 200 to 400 strokes per minute.
 4. The process of claim 1, wherein a needle penetration per square inch (NPPSI) of said loom is one from a range of 200 to
 450. 5. The process of claim 1, wherein a needle density of said needle board is one from a range of 75 to 115 needles per linear board inch.
 6. The process of claim 1, wherein said production width of said loom is a multiple of 30, 45, 36, or 72 inches, wherein a maximum production width is 160 inches.
 7. The process of claim 1, wherein a scrim weight is one from a range of 8 to 34 grams per square meter.
 8. The process of claim 1, wherein a loom speed is one of a range of 12 to 30 feet per minute.
 9. The process of claim 1, wherein a batting weight is one of a range from 70 to 300 grams per square meter.
 10. The process of claim 1, wherein a loom punch speed is approximately 400 strokes per minute, an NPPSI is one of a range from 350 to 450, said scrim is a weight of approximately 17 grams per square meter, and a loom speed is approximately 25 feet per minute. 